Metallizing-furnace.



E. P. MATHEWSON L F. LAIST.

MBTALLIZING PURNACE.

APPLICATION FILED DEG. s, 191s.

1,094,802., Patented Apr. 28, 1914.

5 SHEETS-SHEET 1.

ATTOR "EI".

E. P. MATHBWSON & F. LAIST.

METALLIZNG FURNAGE.

AYPLIOATION FILED DEG. 3, 191s.

1,Q94,802. Patented Apr.28,1914

5 SHEETS-SHEET Z.

E. P. MATHEWSON & F. LAIST.

MBTALLIZING FURNAGB.

APlLIoATION FILED DBG. 3, 191s.

Patented Apr. 28, 1914.

5 SHEETS-SHEET 3.

WIJVESSES.- 52M? Q,

' E. P. MATHBWSON L P. LAIST.

METALLIZING PURNAGE.

APPLICATION FILED DBG, s, 191s.

1,094,802', Patented Apr. 28, 1914.

5 SHEETS-SHEET 4.

B1' v l E. P. MATHEWSON & P. LAIST.

METALLIZING PURNAGE.

APPLICATION FILED DEG. 3, 1913.

1,094,802, Patented Apr. 28, 1914.

5 SHEETS-SHEET 5.

ATTOR 'E Y.

llllylllilul) P. MATHEWSON AND FREDERICK LAIST, 0F ANACONDA, MONTANA.

METLmzING-FURNACE Specification of Letters latent.

Application led December 3, 1913. Serial No. 804,415.

To all whom t may concern Be it known that we, EDWARD P. MATHEW.- SON and FREDERICK LAIsr,- citizens of the United States, residing at Anaconda, in the county of Deer Lodge and State of Montana. have ini ented certain new and useful Improvements in lWIetallizing-Furnaces, of

vwhich the following is a full, clear, and

exact description, reference being ha-d to the accompanying drawings, forming a part hereof.

Our invention has relation to improvements in metallizing furnaces, that is to say, furnaces in which reduction of an ore or oXid of a metal may be effected without fusion of the charge; and it consists in the novel features of construction more fully set forth in the specificatie-mand pointed out in the claims.

kln the drawings, Figure l is a combined elevation and vertical middlesection of our improved furnace; Fig. 2 is a middle vertical section of the furnace taken at right angles to Fig. l, parts being in elevation and partly broken, and being on a larger scale than Fig. l; Fig. 3 is a top plan of the furnace; Fig. 4 is a horizontal section through the top hearth taken on the line les of Fig. l; Fig. 5 is a similar section through lthe third hearth (from the top) or bottomoxidizing hearth, on the line 5 5 of F ig. l; Fig. 6 is a. sectional det-ail showing the coal-chute tapping the-roof of the third hearth and discharging into the fourth hearth or first reduction hearth, the section being taken along a radial vertical plane thro-ugh the axis of the furnace; Fig. 7 is a. horizontal section taken through the lower mu'tlie or combustio-n chamber on the line 7-7 of Fig. Il; and Fig. 8`is a horizontal section of the bottom hearth on the line 8 8 of Fig. l.

The present invention is specically directed to improvements in roasting furnaces of the rotary or McDougal type, which, as well understood in the art, comprise aseries of superposed intercommunicating he-arths in which the ore (or other material) treated in one hearth drops onto the hearth immediately beneath, the last or bo-ttom hearth ofthe series discharging the finished product or calcine.

The object of our invention is to so Inodify the construction of a McDougal furnaceI as to malte the same subserve not vonly the purpose vof roasting the ore, but of reducing the oxids of the metals of the roasted calrateatea am. as, ieia.

cines to the metallic state at temperatures below the point of fusion-of the charge, whereby the resulting product is discharged from the furnace/as a sponge or pulverulent mass, the metal constituent of which is distributed in the form of small particles throughout. t-he gangue with which it is associated. A McDougal furnace so modified, is eminently adapted to treat iron sulfid ores, particularlypyrite from which a po-rtion of the sulfur has been eliminated by subjecting the same to a partial preliminary roast in another furnace.

The improved furnace possesses further and other advantages which will become apparent from a detailed description of the invention which is as follows Referring' to. the drawings, F/represents the furnace, and a, o, c, d, e, f, the several superposed hearthsor floors in which the material is treated (the present being a siX- hearth multiple-hearth. furnace of the Mc- Dougal type) the material dropping from the upper hearth successively through the several hearths until finally reaching the discharge hoppers D whence the reduced metal or sponge is discharged for further treatment.. As well understood in the art the hearths are provided with central and marginal openings or drop-holes 0, o', respectively, for the passage of the material, the floor of the third hearth c being provided with a single drop-holen for conducting the roasted calcine,to the fourth" hearth Z where the reduction of the' metallic o-Xids begins. The ore (partially roasted in another furnace) is delivered toward the center of the top-hearth a from a charging hopper H, a belt feeder 1 conveying the ore to the desired point in said hearth. As well understood in the art, the furnace is provided with 'a central hollow rotatable rabbleshaft Q from which radiate the series of hollow rabble or st-irrer arms 3 extending into the several hearths and' carrying rakes 4, by which the material is successively fed from one hearth to the hearth immediately beneath it, the shaft and arms being provided with water (or air) circusol l-ating pipes P, P', respectively, by which V thc rabble' apparatus is kept cool.

The. mechanism by which rotation is imparted to the rabble-shaft and arms though here illustrated,A is not described because well understood by those skilled in the art,

and forming no part of the present invention. Neither is the driving mechanism for the belt-feeder 1 described (although illustrated) for the same reason.

At a convenient point opposite the furnace is mounted a coal hopper E which discharges onto a belt-feeder 5, the lat-ter delivering the crushed coal to a chute 6 which in turn conveys the same through the floor of the hearth c into the fourth hearth CZ, said chute tapping said Hoor at a point adjacent the drop hole o, whereby the roasted calcine discharges fro-1n the hearthV c into the hearth ,d in conjunction' with the coal from the chute G. The rakes 4 in said hearth CZ move the calcine (oxidized ore and gangue) and coal toward the central drop hole 0 in the floor of said hearth (al)v and mix them thoroughly.` lt may be stated in passing that the driving mechanism for the belt-feeder 5 is actuated from the driving mechanism for the beltfeeder 1 by a belt 1B, whereby the coal is -fed to the hearth Z concurrently with the feeding of the ore to the hearth a. Any equivalent driving mechanism for the feeds may however, be employed, no claim being made thereto as they are well understood in the art.

Iis pointed out above, the present is a combined roasting and reducing furnace, the charge passing from a sultid to the oxid and finally to the metallic state as it descends through the successive hearths. Assuming that the ore to be reduced is pyrite, the ore is subjected to a preliminary roast in a separate furnace to get rid of the major portion of the sulfur, after which it is placed into the charging hopper lll, and fed to the hearth a. 1n the hearths a, b, c, the partially roasted ore is subjected to further oxidation, the roasting or oxidation in these hearths being carried as far as desired (say to the point of eliminating all but a small percentage of the sulfur). The roasting in the upper hearths (a, b, c) converts the charge into an oxid of iron (barring of course, the small per cent. of sulfid which it may not be necessary to completely decompose for our purpose) which drops through the hole o onto the floor of the fourth hearth a?. 'llhe roasting or oxidation of the charge in the hearths a, b, c, may be accomplished by any suitable direct-firing means; but in the present embodiment of our invention we prefer to re these (roast ling or oxidizing) hearths (a, b, o) by means of oil (or gas) flames, suitable provision being made for this purpose in the shape of pipes 7 disposed about the furnace and conducting the oil by means of nozzles t to the air injectors or nozzles a at the end of the air pipes 8, the inflammable mixture being projected and sprayed into the hearth c through the hollow burners 9 in the furnaceipeaeoa walls, the nozzles t and a being provided with controlling valves e as well understood in the art. In lieu of oil or gas, we may lire the hearth c directly from a lire-box as shown in U. S. Patent on roasting furnace, Number 1,070,490, dat-edI August 19, 1913 issued to Frederick Laist. A portion of the combustion products may escape from the hearth c through an opening 10 into the uptake flue l1, the latter leading to the main flue 12 into which likewise discharge the gas-dues 18 by which the roaster gases from the oxidizing hearths (a, Zi, c) are led out of the furnace. The uptake-flue 11 is provided with a slide or damper la by which all, or a portion of the combustion lproducts and gases from the combustion chambers (presently to be described) discharging into said flue, may be diverted into the hearth c, when it is desiredto heat the oxidizing hearths direct by the gases from said chambers. In fact, the employment of the chamber gases constitutes one of the several ways by which the oxidizing hearths may be tired.

interposed between hearths four (CZ) and five (c), and between hearths five (c) and six (f) are annular combustion chambers C, the roofs of the chambers constituting the floors of the hearths immediately above, and the floors of the chambers constituting the roofs of the hearths immediately beneath. The roofs of the Ichambers are flat with a slight downward slope toward the axis of the furnace, and are composed of tiles la laid so as to overlap one another, and supported by piers 15 of fire-brick resting on the floor of the chamber, the chambers being closed on the side adjacent the axis of the furnace, but opening at their peripheries or outer portions into the flue 11 through passage-ways or openings 10. The chambers C are heated by oil burners 9 supplied with the proper mixture through the oil nozzles t and air nozzles n at the ends of the pipes 7 and 8 respectively, the pipes 8, 8, and 7, 7, each leading to ini dependent sources of compressed air and oil supply respectively (not shown). ln lieu of oil, gas or solid fuel may be used. flearths four and five (CZ, c) are thus converted into mufiies or muflie members being heated byv the combustion chambers (l, hearth six (f) not requiring to be heated, but is heat-insulated so as to conserve to the fullest extent possible the heat of the ore discharged thereinto from the upper hearths. Precautionlis taken to excludeoutside air from the lower (reduction) hearths (d, c, but this is not difficult of accomplishment as the gases of reaction insaid hearths tend to keep the air out. These reaction gases escape through the flue 16 provided with a damper 1'? normally set so 'as to prevent any suction, but rather to produce a slight gas pressure on these floors (d, e, f). The flue 16 is connected to the respective hearths d, c, f, by short pipes p as shown.v A hood 18 tap-ping the Hue 16 is mounted over the coal chute 6 to catch any gases escaping therethrough, the gases collected by the hood being discharged into said flue 16 through pipe 18.

In the operation ofthe furnace, the finely crushed and partially roasted ore (pyrite) is discharged fromV the hopper' H onto the feeder 1, the latter conducting it (through a chute fw) into hearth a, the rakes 4 of the rabble mechanism stirring the charge and causing the same to traverse the heart-hs a, b, c, the ore dropping through the marginal drop-holes o of the rst hearth on to the second hearth, and through the central drop-hole 0 ofthe second hearth onto the third hearth, which as before stated, is provided with a single marginal drop-hole 0- discharging the ore onto the fourthhearth. During the traverse *of the ore charge through the hearths a, b, c, the metallic suld is thoroughly oxidized (to the point of elimination of most of the sulfur) lthe pyrite being converted into the form o-f oxid, usually a mixture of Fe() and Fe203, the hearths a, Z2, c, being for convenience herein denominated as the roasting or oxidizing hearths. As the iron oxid and gangue drop through the hole 0 onto the hearth d there is delivered atthe same time to said hearth (d) the necessary complement of crushed coal discharged through the chute 6 (receiving its supply from the coal hopper Ey and belt-feeder 5) at a point adjacent `(in front or behind) the drop-hole o, the rakes i 4` in said hearth d (and in the hearths 6, f) thoroughly mixing the ore and coal (or equivalent reducing agent), the slight slope of the oors of the hearths d', e, assisting the rakes to secure a thorough intermingling of the ore and co-al, and allowing for expansion. As previously stated, the hearths d, e, (which together with the bottom hearth f may for convenience be denominated as the reduction hearths) are heated from' the chambers C, the heat imparted tothe mixed charge of ore (iron oxid and gangue) and coal (or equivalent fuel) being sufficient to bring about the necessary reaction between the carbon (and hydrogen) of the fuel and the oxygen of the iron oxid. These reactions may be expressed substantially as follows 4 (a) FeO-l-CzFe-l-CO.

mixed with the coal (in the fourth hearth the temperature of the mixture (traversing the reduction hearths) should be kept fbe-f low the point of fusion ofthe charge (this x point being substantially 1800 degrees Fahrenheit). lhe temperature at which carbon reduces iron oxid corresponds to that at rwhich metallic iron decomposes vapor of From the foregoing reactions (a, b, c, d) it will be seen that the gases constituting the products of the react-ion are in the main CO and H, the C0 being of course, the principal product. These gases are conducted out of the hearths (d, f) through the pipes p and ,flue 16, into the atmosphere or to any suitable point of consumption (not shown), the bottom of the flue 16 being closed and resting on the bottom floor L, the furnace being provided with a series ofy floors L, L, L, (indicated conventionally) to obtain ready access to the dierent hearths.

The reactions of reduction above'indicated (reactions a, b, c, d) assume ofcourse, that no air is allowed to enter the hearths, d, c, f, for were air admitted, the oxygen thereof would reoxidize the metal (Fe), an objection not to be tolerated. These reactions further assume that the reduction hearths (ci, e) derive their heat from the chambers C, C. We may however, dispense with the combustion chambers C and supply the necessary heat to these hearths (fl, e) by feeding in an excess of carbon (coal) and admitting sufficient air to burn this excess, the heat from the burning fuel being suflicient to raise the temperature of the ore charge and the balance of the carbon to bring about the reducing reaction between the iron oxid and carbo-n. In that event the heat from this excess of burning carbon would simply take the place of the chambers. The air for burning this carbon excess could be admitted to one or all of the bo-ttom floors (through the furnace doors A, or otherwise), in which event the coal (and gases therefrom) would burn directly in the charge itself or immediately over it.

In the practice of our invention the rate of travel or advance of the charge through thc several hearths must necessarily be commensurate with the rate at which the roast-- ing or oxidation and subsequent `reduction can take place; and we nd that 'by impart- Aing to the rabble arms a speed of rotation izo lia

ous heating, but it should be properly insulated so as to conserve the heat inherent in the charge dropping into this hearth from the hearth above. ln the hearth f the metal and gangue are raked toward the center, Where they drop through the chutes m into the hoppers D. rllhe rabble shaft and arms are preferably coated with a layer of fire clay or other poor conductor of heat (not shown The final product of our process is a sponge"-a mixture of iron and gangue-from which the metal may be recovered by means of a magnetic separator or by any other method known to the art.

Cbviously, the atmosphere Within the three lower or reduction floors (Z, e, f, must be a reducing one, and While We prefer to establish and maintain such an atmosphere by the construction of the chambers C operating Without access of air to the said hearths, ,such an atmosphere may be estab! lished by dispensing With the chambers and employing an excess of carbon inconjunction with air admitted to burn this excess as above pointed out. We may also establish such a reducing atmosphere byr dispensing with the chambers C and heating the hearths al and e by means of a reducing flame projected through the Walls thereof (on the order of the oil burners for the hearth c, and chambers C), such reducing flame being made from oil, gas, coal, coal-dust or equivalent fuel. the chambers C as shown, and the exclusion 'of air from the reduction hearths (d, e, f).

removes the gases (CU and H) forming the by-products of the reducing reaction between the coal and iron oXids in the hearths CZ, e, f. A portion of the gases from the hearth c may escape through the passage 10 into the flue ll, the said passage l0 being availed of to fire the hearth c direct from the chambers C by closing the slide or damper la as already explained.

"Whatever be the ultimate form of construction the furnace may assume, the roasting hearths a., Z), c, Will be heated by direct lire by means of the oil-burners 9 or their equivalents; the reduction hearths d, e, f, will have maintained therein a reducing atmosphere and be heated independently by the chambers C or by any of the equivalent methods pointed out aboveg and the furnace @ur preference however is for will be provided With suitable means affording escape for the various gases resulting from the several reactions involved in the successive steps of oxidation and reduction. rfhe passages 10, 10, are provided With slide or damper openings s for obvious purposes.

rlhe present furnace may be considered as a combined roasting and reducing metallurgical furnace of the McDougal type, combining as it does all the attributes of a Mc- Dougal roaster, with an apparatus treating an oXid of iron With suitable carbonaceous fuel to effect the reduction to the metallic State;

Features of furnace construction shown but not alluded to are Well understood in the art and require no description in the present connection.

Having described our invention, what We claim is:

l. A combined oxidizing and reducing metallurgical furnace comprising a series of superposed intercommunicating hearths discharging successively into one another, a direct liring means coperating With an intermediate hearth, a combustion chamber interposed between, the hearth immediately beneath the direct-fired hearth andthe next hearth below, a flue for discharging the Waste gases from the combustion chamber to a point outside the furnace, and means in said flue for diverting such Waste gases into the direct-red hearth.

2. A combined oxidizing and' reducing metallurgical furnace comprising a series of superposed intercommunicating hearths discharging successively into one another, means for -direct-ring an intermediate hearth of the series, a muHe-hearth below the directfired hearth, means for conducting the Waste gases from the combustion chamber identified With the` muile hearth to a point outside the furnace, and means for diverting said Waste gases into the directfired hearth.

3. A combined oxidizing and reducing metallurgical furnace comprising a series of superposed intercommunicating hearths discharging successively into one another, means for direct-firing an intermediate hearth of said series, a mufHe-hearth con` tig'uous to said direct-fired hearth, a main Waste-gas flue, means for conducting the waste gases from the combustion chamber identified With the muffle-hearth to said main flue, a gas flue for conducting the Waste gases from the several oxidizing hearths to the main Hue, means for diverting. any desired portion of the Waste gases from the inutile-hearth combustion chamber into the direct-fired hearth, and independent of superposed intercommunicating hearths discharging successively into one another, a direct-ring means cooperating with an intermediate hearth, combustion chambers interposed between the hearth immediately beneath the direct-fired hearth and the next hearth below and the last hearth and the succeeding lower hearth, means independent ofthe direct-firing means for heating said combustion chambers, an uptake-flue for conducting away the combustion products from said chambers, a damper in said flue, means below the damper for establishing communication between said flue and the direct-red hearth, means for feeding carbonaceous fuel to the hearth immediately beneath the direct-fired hearth,

'means in the hearths below the direct-fired hearth for thoroughly commingling the fuel with the roasted charge delivered to said hearths, a ue for conducting the roaster gases from the direct-fired heart-h and the hearths above the same, and means for conducting from said reduction hearths the gases evolved from the react-ion of reduction.

5. A combined oxidizing and reducing metallurgical furnace comprising a series of superposed intercommunicating hearths discharging successively into one another, means for direct-firing an intermediate heart-h of the series, a muilie-hearth contiguous to said direct-fired hearth, means for discharging at a point outside the furnace the waste gases of the muffle-heating means, means for conducting "away the waste gases from the direct-fired hearth and heart-hs above the same, means for diverting the waste gases of the muHe-heating means into the direct-fired hearth, means for feeding reduction fuel to the Vmuflle-hearth, and means for conducting away the gases evolved from the reaction 0f reduction to a point outside the furnace.

6. In combination with an upper directfired hearth traversed by the material to be treated, a lower muflie-hearth receiving the calcines from the upper hearth, means independent of the direct-ring means aforesaid for heating the munie-hearth, means for conducting tothe mufle-hearth a charge of reduction fuel, means in the mufie-hearth for mixing said fuel and calcines discharged thereinto from the upper hearth, a gas-discharge iue leading from the muiie-heating means to a point outside the furnace, and controllable means for establishing communication between said flue and the direct-fired hearth.

7. The combination with an upper directfired hearth traversed by the material to be treated, a lower munie-hearth receiving the calcines from the upper hearth, means for heating` the mutHe-he'art-h, means for con-l ducting to the muflie-hearth a charge of reduction fuel, means for mixing said fuel, y

and calcines discharged into the mufflehearth, means for conduct-ing any predetermined portion of the waste gases from the munie-heating means to a point outside the furnace, means for diverting another portion of said gases into the direct-fired hearth and independent means for conducting away the gases fro-m the direct-fired hearth.

8. The combination with an upper directfired hearth traversed by the material to be treated, a lower muifle-he'arth receiving the calcines from the upper hearth, means for heating the munie-hearth, means for conducting to the munie-hearth a charge of reduction fuel, means for mixing said fuel, and calcines discharged into the .mufilehearth, means for normally conducting the waste gases from the muffle-heating means to a point outside the furnace, independent means for conducting "away the waste gases from the direct-tired hearth, and means under the control of the operator for diverting the waste gases from the munie-heating means into the direct-fired hearth.

In testimony whereof we affix our signatures in presence of two witnesses.

EDWARD P. MATHEVVSON. .FREDERICK LAIST. Witnesses:

E. M. DUNN, MARTIN MARTIN. 

